Prep table food bag

ABSTRACT

The prep table food bag includes an air tight sealed food bag that is suspended by a Gastronorm sized lip frame that sits on the pan rails of a prep table. The prep table food bag is able to function as an air tight sealed food bag package during storage and transport and is also able to function as a food pan on the pan rails of a prep table.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Patent Cooperation Treaty (PCT) application claims the benefit of U.S. Provisional Patent Application No. 62/921,856 filed Jul. 12, 2019.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to prep table food bags. More particularly, the present invention relates to devices and methods for disposable air tight sealed food bag packages that protect and preserve food contents during transport and fit onto pan rails of prep tables.

2. Description of Related Art

For over 50 years, the food pans designed for sitting on the pan rails of prep tables have proven to be an integral tool in the world's restaurant kitchens. Many foods are pre-sliced, pre-shredded and are ready to cook and use in the kitchen upon arrival. The practice of storing and transporting pre-sliced foods in disposable plastic bags has proven desirable for the following reasons:

A. Plastic bags are cheaper than plastic pans.

B. Plastic bags take up less space than plastic pans.

C. Plastic bags are lighter than plastic pans.

D. Plastic bags result in less material waste for the environment.

E. Plastic bags provide better barrier seal and protection for longer shelf life.

F. Plastic bags are easier to vacuum seal without creating flex cracks.

G. Plastic bags are more durable for storage and transport than plastic pans.

For these reasons, even foods such as jalapenos and olives are now commonly packaged in plastic bags rather than cans. In the past and current situations, kitchens still have to transfer foods from their original packaging to a Gastronorm sized food pan. Gastronorm size refers to the internationally accepted sizes of food pans designed for sitting on the pan rails of the prep tables. The following sizes are the Gastronorm sizes used today: GN2/1 650×530 mm, GN1/1 530×325 mm, GN2/3 354×325 mm, GN2/4 530×162 mm, GN1/2 325×265 mm, GN1/3 325×176 mm, GN1/4 265×162 mm, GN1/6 176×162 mm, GN1/9 108×176 mm, GN2/8 325×132 mm, GN1/12 162×88 mm, GN2/24 132×108 mm, GN1/18 108×88 mm. Standard depths are 20 mm, 40 mm, 65 mm, 100 mm, 150 mm, 200 mm and 300 mm. Gastronorm sized food pans designed for sitting on pan rails of prep tables are fitted uniformly with a one half inch (1.27 cm) flange surrounding the top edge of the food pan. The Gastronorm sizes listed above relate to the outside length and outside width of the food pan's flange. The flange is the part of the food pan that sits on the pan rails of the prep table and is responsible for suspending the food pan within the refrigerated cabinet below the pan rails.

The kitchen staff must be sure to use a clean environment and clean hands while transporting food to the prep table food pans. Oftentimes, the food will be exposed to room temperature and the open air for an extended period of time during this transfer to food pans. This poses a risk of bacteria growth, food borne illnesses, potential viruses and potential cross contamination. A label identifying the food in food pan along with a revised expiration date must be attached to each and every food pan to be code compliant. The amount of food placed in food pans must be consistent to ensure accurate food inventory counts.

The food pans occupy additional space within the refrigerator along with the boxes the food was shipped in. Once food is depleted from the food pans, the food pans have to be washed thoroughly incurring hot water, dish soap, sanitizer and labor cost. Prep table food pans are vulnerable to food theft especially when sitting in a walk-in fridge as employees are beyond prying eyes and the lid on food pans is merely sitting on top of food pan and can be easily lifted and food stolen and eaten. Additionally, employees are more likely to steal expensive food items such as meats and cheeses rather than vegetables adding considerably to food cost. Prep table food pans are also vulnerable to tampering by prankster employees which can expose restaurant owner to legal liabilities, as well as loss of faith among the customer base.

Once food is unsealed and removed from its original packaging, the shelf life is greatly reduced leading to potential food spoilage and unfreshness which results in additional food cost and unsatisfied customers. The reduction in shelf life creates a challenge for kitchen staff and management. If too much food is removed from original packaging and placed into food pans, then the food could spoil. If too little food is placed into food pans, then the potential of running out of prefilled food pans during a dinner or lunch rush is increased. These are the challenges that all kitchens face when using prep tables to hold food within arm's reach of food assembly counter tops.

Currently in the field of food preparation, only rigid pans and trays sitting on the pan rails of the prep tables are utilized. The word pan rails suggest that only rigid pans can sit on the pan rails. The current invention is not a pan but is a bag that employs a Gastronorm sized lip frame that sits on the pan rails, suggesting for the first time that the rails can now be referred to by some as bag rails.

There are clearly many advantages for pre-sliced and pre-shredded foods to remain in their original food package bags and to be able to go from the box they are shipped in immediately to the pan rails, without the need for food pans. Such a solution would circumvent the need for food pans and all the challenges they present. As more and more foods are pre-sliced and pre-shredded than ever before, the demand and need in the field for a food package bag that sits on the pan rails of a prep table will substantially grow.

SUMMARY OF THE INVENTION

The present invention is a solution to all the challenges presented in the field relating to prep table food pans. The prep table food bag is able to hold food throughout transport, storage and placement on the pan rails of a prep table. The prep table food bag comprises an air tight sealed food bag affixed underneath a Gastronorm sized lip frame that sits on the pan rails of a prep table and suspends the food bag in a cabinet of the prep table. Food is only removed from prep table food bag by only one set of hands, thus reducing chances of cross contamination. Food is always being refrigerated even while the prep table food bag is being opened on pan rails. Prep table food bags are able to remain in the box they were shipped in until they are needed on the pan rails and this provides added protection for the food they contain. Since prep table food bags are air tight sealed, they are tamper-resistant and protect food from contaminates until prep table food bags are opened on pan rails of a prep table in plain view of all kitchen staff.

Food theft is greatly reduced before food reaches the pan rails when prep table food bags are employed. In this case, employees would have to try to steal food after it reaches the pan rails. This can result in significant savings. 90% of all food theft occurs out of sight in a walk-in refrigerator. Prep table food bags can and should have a label printed on them identifying food contents and expiration dates. This helps eliminate employees mistakes as labels are printed at warehouse. Prep table food bags provide consistent weight of food contents until being opened on pan rails. This aids in accurate food inventory counts. Since prep table food bags remain sealed until being placed on the pan rails, this assures greater freshness of food product and happier customers.

The prep table food bag is discarded into a trash receptacle once food has been depleted resulting in reduced hot water use, less dish soap and sanitizer and labor cost thus saving money. Fewer dishes to wash results in less water ending up on the floor thus reducing potential slips and falls and the liability this presents. Both customers and employees and management have greater assurance that food is more sanitary and fresher when prepackaged in prep table food bags than when placed into prep table food pans.

These and other features and advantages will be apparent from reading of the following detailed description and review of the associated drawings. It is to be understood that both the forgoing general description and the following detailed description are explanatory and do not restrict aspects as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a preferred embodiment of a prep table food bag 10.

FIG. 1A illustrates an exploded perspective view of food bag 10.

FIG. 2 illustrates a perspective view of an alternative embodiment of a prep table food bag 20.

FIG. 2A illustrates an exploded perspective view of food bag 20 with the lid 202 partially peeled back.

FIG. 3 illustrates a perspective view of an alternative embodiment of a prep table food bag 30.

FIG. 3A illustrates an exploded perspective view of food bag 30 with the seam 309 sealed shut.

FIG. 4 illustrates a traditional 1/3 Gastronorm sized prep table food “pan” 900.

FIG. 4A illustrates a preferred embodiment of a 1/3 Gastronorm prep table food bag 10.

FIG. 5 illustrates a traditional 1/6 Gastronorm sized food pan 900A.

FIG. 5A illustrates an embodiment of a 1/6 Gastronorm sized prep table food bag 10A.

FIGS. 6, 7, and 8 illustrate a preferred method of manufacture of the prep table food bags using a thermoformer 1000 in concert with a glue dispenser 1100, a denester 1200, and a trimmer 1300.

FIG. 9 illustrates a preferred method of manufacture of the prep table food bags showing an assembly line process.

FIG. 10 illustrates the process for prep table food bags 10 able to go directly from the box 150 to the pan rails 165 of a prep table 160 with no preparation required.

FIG. 11 illustrates a draw string resealable lid mechanism 401 that is pulled apart at the top seam of the food bag 40.

FIG. 12 illustrates a touch sensitive adhesive resealable lid mechanism 501 at the top seam of the food bag 50.

FIG. 13 illustrates a zip lock resealable lid mechanism 601 at the top seam of the food bag 60.

FIG. 14 illustrates a deep end bag 70.

FIG. 15 illustrates a shallow end bag 80.

FIG. 16 illustrates an embodiment 90 with multiple sealed food bags 901 underneath only one lip frame 902.

FIG. 17 illustrates an embodiment 95 with a lip frame 97 and collar 98 overhang more than a half inch (1.27 centimeters) over the base 96.

DETAILED DESCRIPTION OF EMBODIMENTS

The following descriptions relate principally to preferred embodiments while a few alternative embodiments may also be referenced on occasion, although it should be understood that many other alternative embodiments would also fall within the scope of the invention. The embodiments disclosed are not to be construed as describing limits to the invention, whereas the broader scope of the invention should instead be considered with reference to the claims, which may be now appended or may later be added or amended in this or related applications. Unless indicated otherwise, it is to be understood that terms used in these descriptions generally have the same meanings as those that would be understood by persons of ordinary skill in the art. It should also be understood that terms used are generally intended to have the ordinary meanings that would be understood within the context of the related art, and they generally should not be restricted to formal or ideal definitions, unless and only to the extent that a particular context clearly requires otherwise. Synonymous or equivalent terms may be used in different instances in the specification and should not be construed to limit the invention. For example, terms referred to as broad or synonymous terms in the description or drawings can be replaced with broad or synonymous terms in other descriptions in the specification or drawings. In light of the present disclosure, those of ordinary skill in the art should also appreciate that many changes can be made relative to the disclosed embodiments while still obtaining a comparable function or result without departing from the spirit and scope of the disclosure.

For purposes of these descriptions, a few wording simplifications should also be understood as universal, except to the extent otherwise clarified in a particular context either in the specification or in particular claims. The use of the term “or” should be understood as referring to alternatives, although it is generally used to mean “and/or” unless explicitly indicated to refer to alternatives only, or unless the alternatives are inherently mutually exclusive. Furthermore, unless explicitly dictated by the language, the term “and” may be interpreted as “or” in some instances. When referencing values, the term “about” may be used to indicate an approximate value, generally one that could be read as being that value plus or minus half of the value. “A” or “an” and the like may mean one or more, unless clearly indicated otherwise. Such “one or more” meanings are most especially intended when references are made in conjunction with open-ended words such as “having,” “comprising” or “including.” Likewise, “another” object may mean at least a second object or more. Thus, in the context of this specification, the term “comprising” is used in an inclusive sense and thus should be understood as meaning “including, but not limited to.” As used herein, the use of “may” or “may be” indicates that a modified term is appropriate, capable, or suitable for an indicated capacity, function, or usage, while considering that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable.

FIG. 1 illustrates a perspective view of a preferred embodiment of a prep table food bag 10. The term “bag” is used here to describe a container made of flexible material for storing and transporting food. A “bag” is in contrast to a food “pan” which is made of a rigid material. The food bag 10 is shown sealed (“airtight”) and can include a pull tab 103 affixed to a lid 102, with a product type, date packaged, and date of expiration.

FIG. 1A illustrates an exploded perspective view of food bag 10. The food bag 10 includes a bag base 105 with a top surrounding collar 101 and the lid 102 is affixed to the top of collar 101. A pull tab 103 can be affixed or embedded within the lid 102. An adhesive may be used to affix or embed the pull tab 103 in the lid 102. A user can remove the pull tab 103 to break the seal and access the food contents 110 of the bag 10. The pull tab 103 can also be used to reseal the bag 10. The type of food contents 110 can vary and contents 110 are shown in several embodiments in broken lines and are not part of the structure of the invention. The lid 102 is affixed to and underneath a lip frame 104. The lip frame 104 is preferably rigid and Gastronorm sized, although the sizing can be modified. As will be understood by those of ordinary skill in the art, Gastronorm or Gastro-Norm is a standard for kitchenware tray and container sizes in the food industry. The lip frame 104 extends beyond (“overhang”) the neckline 106 of the bag base 105. The “neckline” 106 is defined herein this specification as the top perimeter of the bag base 105. The bag base 105 is preferably constructed of a flexible material such as plastic. Preferably, the lip frame 104 overhangs the base 105 by at least half an inch (1.27 centimeters), although greater distances can also be employed. The lip frame should overhang the surrounding neck line of food by at least a half inch (1.27 centimeters) to prevent a food bag from touching or getting close to neighboring food bags and food pans, thereby choking air flow.

FIG. 2 illustrates a perspective view of an alternative embodiment of a prep table food bag 20. The sealed food bag 20 includes a bag base 105 with a top surrounding collar 201 and a lid 202 which covers over the top portion of the lip frame 204. FIG. 2A illustrates an exploded perspective view of food bag 20 with the lid 202 partially peeled back. The lip frame 204 overhangs the neckline 206 of the bag base 205. Preferably, the lip frame 204 overhangs the base 205 by at least half an inch (1.27 centimeters), although other distances can also be employed. The lid 202 is flexible and overhangs the lip frame 204, enabling a user to grip the lid 202 and pull to break the seal and access the food contents of the bag 20.

FIG. 3 illustrates a perspective view of an alternative embodiment of a prep table food bag 30. The sealed food bag 30 includes a flexible seam 309 on top of the bag base 305 which can be opened. FIG. 3A illustrates an exploded perspective view of food bag 30 with the seam 309 sealed shut. The bag base 305 does not have the top surrounding collar as shown in FIGS. 1A and 2A, so the lip frame 304 can be affixed to the top perimeter (neckline) 306 of the bag base 305. The lip frame 304 extends beyond (“overhangs”) the neckline 306 of the bag base 305. As shown in FIG. 3, the seam 309 can be opened to break the seal by pulling in opposite directions 307, 308.

FIG. 4 illustrates a traditional prep table food “pan” 900, in contrast to FIG. 4A which illustrates a preferred embodiment of a prep table food bag 10. The lip frame 104 of the food bag 10 has similar outer dimensions (length and width) to the dimensions of a flange 904 of a prep table food “pan” 900. FIG. 4 and FIG. 4A are examples showing the comparable sizes of the 1/3 Gastronorm sized food pan 900 and the prep table food bag 10. Similarly, FIG. 5 and FIG. 5A are examples showing the comparable sizes of the 1/6 Gastronorm sized food pan 900A and the prep table food bag 10A.

FIG. 6 illustrates a preferred method of manufacture of the prep table food bags using a thermoformer 1000 (former, filler, and sealer), although other methods of manufacture may be employed. The thermoformer 1000 can work in concert with a glue dispenser 1100, a denester 1200, and a trimmer 1300 (as shown in FIG. 7 and FIG. 8).

Referring to FIG. 8, a flat sheet of plastic 1002 is drawn from a rollstock 1001 over a cavity mold 1003 and the plastic sheet 1002 is vacuumed downward while the sheet heats up. This heating process 1004 causes the plastic to melt within and take the shape of the cavity 1003. Once the plastic cools, the cavity 1003 is removed, and the plastic bag base 105 is the same shape as the cavity 1003 from which it is drawn.

Referring to FIG. 9, the plastic sheet around the top of plastic bag base 105 forms a collar 101. The collar 101 is part of the bag base 105 and they are connected as part of a monolithic structure. The collar 101 and bag base 105 are then advanced under the filler 1400 where food is either manually or mechanically placed into the bag base 105. The collars 101 between bag bases 105 are connected from bag to bag in an assembly line format. The collars 101 and bag bases 105 are advanced through the sealer 1500 where a plastic sheet lid 102 from rollstock 1011 is drawn and sealed onto the top collar 101 of the bag base 105 with an adhesive pull tab 103 embedded in the lid 102 over the bag base 105. Next, the food bag 10 is advanced under a glue dispenser 1100 in which the glue is deposited onto the top of the collar 101 and perimeter of the lid 102 of the food bag 10. The food bag 10 is then advanced under the denester 1200 in which a lip frame 104 is placed onto glue and is affixed to the lid 102. The food bag 10 and the lip frame 104 are advanced through the trimmer 1300 where blades cut and remove plastic collar sheeting in between lip frames 104. This enables the prep table food bags 10 to emerge separate and independent of each other, ready to be placed into a box 150 for distribution to an end user.

Referring to FIG. 10, once a box 150 is received by an end user, the prepackaged prep table food bag 10 is able to go directly from the box 150 to the pan rails 165 of a prep table 160 with no preparation required. When the prep table food bag 10 has been depleted of its food content, it is discarded into the trash receptacle 170 and replaced with a new bag 10.

FIGS. 11-13 illustrate alternative embodiments of prep table food bags with resealable lids. Resealable lid mechanisms can be implemented at the top seam of the food bags, above the bag base 105. The bag base 105 itself is not altered in the disclosed embodiments. FIG. 11 illustrates a drawstring resealable lid mechanism 401 that is pulled apart to open at the top seam of the food bag 40. FIG. 12 illustrates a touch sensitive adhesive resealable lid mechanism 501 at the top seam of the food bag 50. FIG. 13 illustrates a zip lock resealable lid mechanism 601 at the top seam of the food bag 60.

Various alternative prep table food bag embodiments are illustrated in FIGS. 14-17. FIG. 14 illustrates a deep end of a bag 70 and FIG. 15 illustrates a shallow end of a bag 80. These embodiments are utilized when the pan rails on a prep table are inclined and the food bag needs to be prevented from draping against the lower inside cabinet wall, thereby choking air flow in the cabinet. FIG. 14 illustrates a bag 70 with a zip lock resealable lid mechanism 701. FIG. 15 illustrates a bag 80 with a pull tab 803 affixed to a lid 802.

FIG. 16 illustrates a prep table food bag embodiment 90 with multiple sealed bags 901 underneath only one lip frame 902 to keep food fresher and for multiple food items used in conjunction next to each other. FIG. 17 illustrates an embodiment 95 with a lip frame 97 that overhangs more than a half inch (1.27 centimeters) over the base 96. The lip frame should overhang the surrounding neck line of food by at least a half inch (1.27 centimeters) to prevent a food bag from touching or getting close to neighboring food bags and food pans, thereby choking air flow. 

1. A prep table food bag comprising: a. a rigid Gastronorm sized lip frame; b. a bag base; c. the lip frame operatively connected to the bag base; d. wherein the lip frame overhangs a neckline of the bag base; e. wherein the lip frame is configured to sit on pan rails of a prep table; and f. wherein the prep table food bag is prepackaged and sealed.
 2. The food bag of claim 1, wherein the lip frame overhangs the neckline of the bag base by at least 1.27 centimeters.
 3. The food bag of claim 1, further comprising a touch sensitive adhesive resealable lid mechanism at a top seam of the food bag.
 4. The food bag of claim 1, further comprising a zip lock resealable lid mechanism at a top seam of the food bag.
 5. The food bag of claim 1, further comprising a drawstring resealable lid mechanism at a top seam of the food bag.
 6. The food bag of claim 1, wherein the bag base comprises: a. a shallow end; and b. a deep end on the opposite side from the shallow end.
 7. The food bag of claim 1, wherein the food bag further comprises a plurality of sealed bags underneath the lip frame.
 8. A prep table food bag comprising: a. a rigid Gastronorm sized lip frame; b. a bag base comprising a collar; c. a lid affixed to the collar; d. the lip frame affixed to the lid or the collar; e. wherein the lip frame overhangs a neckline of the bag base; f. wherein the lip frame is configured to sit on pan rails of a prep table; and g. wherein the prep table food bag is prepackaged and sealed.
 9. The food bag of claim 8, wherein the lid is embedded with an adhesive pull tab.
 10. The food bag of claim 8, further comprising a touch sensitive adhesive resealable lid mechanism at a top seam of the food bag.
 11. The food bag of claim 8, further comprising a zip lock resealable lid mechanism at a top seam of the food bag.
 12. The food bag of claim 8, further comprising a drawstring resealable lid mechanism at a top seam of the food bag.
 13. The food bag of claim 8, wherein the bag base comprises: a. a shallow end; and b. a deep end on the opposite side from the shallow end.
 14. The food bag of claim 8, wherein the food bag further comprises a plurality of sealed bags underneath the lip frame.
 15. A prep table food bag comprising: a. a rigid Gastronorm sized lip frame; b. a bag base comprising a collar; c. the lip frame affixed to the collar; d. a lid affixed to the lip frame; e. wherein the lid overhangs an end of the lip frame; f. wherein the lip frame is configured to sit on pan rails of a prep table; and g. wherein the prep table food bag is prepackaged and sealed.
 16. The food bag of claim 15, wherein the lid is embedded with an adhesive pull tab.
 17. The food bag of claim 15, further comprising a touch sensitive adhesive resealable lid mechanism at a top seam of the food bag.
 18. The food bag of claim 15, further comprising a zip lock resealable lid mechanism at a top seam of the food bag.
 19. The food bag of claim 15, further comprising a drawstring resealable lid mechanism at a top seam of the food bag.
 20. The food bag of claim 15, wherein the bag base comprises: a. a shallow end; and b. a deep end on the opposite side from the shallow end; and c. wherein the food bag further comprises a plurality of sealed bags underneath the lip frame.
 21. (canceled) 